CARBONE PowerMaster205 Operator's Manual
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CARBONE PowerMaster205 Operator's Manual

Dc inverter ac/dc tig/dc stick/cut 4in1 machine
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PowerMaster205
Safety, Setup and General Use Guide
REV.2 0 00146-16
Issue Date: May. 10, 2016
Manual No.: 0-1536
(Suitable for 1x220V)
Operators's Manual
DC INVERTER
AC/DC TIG/DC STICK/CUT
4IN1 MACHINE
EMPRESAS CARBONE S.A.
Calle 5ta. Rio Abajo, Panamá, Panamá
Telefonos: (507) 3916309 / 3916313
www.empresascarbone.com

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  • Page 1 AC/DC TIG/DC STICK/CUT 4IN1 MACHINE (Suitable for 1x220V) Operators’s Manual Safety, Setup and General Use Guide EMPRESAS CARBONE S.A. REV.2 0 00146-16 Calle 5ta. Rio Abajo, Panamá, Panamá Issue Date: May. 10, 2016 Telefonos: (507) 3916309 / 3916313 Manual No.: 0-1536...
  • Page 2 Dear Customer, Thank you for selecting the our machine. We appreciate you as a customer and hope that you will enjoy years of use from your welder. Please go directly to the our website to register your unit and receive your warranty information. Your unit registration is important should any information such as product updates or re-calls be issued.
  • Page 3 We want you to take pride in operating our machine as much pride as we have taken in making this product for you. Please read all information in this manual before operation PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY When this equipment is shipped, title passes to the purchaser upon receipt from the courier.

  • Page 4: Safety Precautions

    SAFETY PRECAUTIONS We are dedicated to providing you with the best possible equipment and service to meet the demanding jobs that you have. We want to go beyond delivering a satisfactory product to you. That is the reason we offer technical support to assist you with your needs should an occasion occur. With proper use and care your product should deliver years of trouble free service.
  • Page 5 SAFETY PRECAUTIONS These safety precautions are for protection of safety and health. Failure to follow these guidelines may result in serious injury or death. Be careful to read and follow all cautions and warnings. Protect yourself and others. Welding and cutting processes produce high levels of ultraviolet (UV) radiation that can cause severe skin burn and damage.
  • Page 6 SAFETY PRECAUTIONS WARNING! Persons with pacemakers should not weld, cut or be in the welding area until they consult with their physician. Some pacemakers are sensitive to EMF radiation and could severely malfunction while welding or while being in the vicinity of someone welding. Serious injury or death may occur! Welding and plasma cutting processes generate electro-magnetic fields and radiation.
  • Page 7 SAFETY PRECAUTIONS WARNING! Electrical shock can kill. Make sure all electrical equipment is properly grounded. Do not use frayed, cut or otherwise damaged cables and leads. Do not stand, lean or rest on ground clamp. Do not stand in water or damp areas while weld-ing or cutting. Keep work surface dry.

  • Page 8: Table Of Contents

    TABLE OF CONTENTS Page SAFETY PRECAUTIONS..........Installation.............Section A Technical Specifications..........A-1 Output Amps %duty cycle ..........A-2 Select Suitable Location..........A-3 Stacking ..............A-3 TRANSPORT - UNLOADING ..........A-3 Tilting...............A-3 Environmental Area ............A-3 Machine Grounding and High Frequency Interference Protection ..A-4 Input Connections ...........A-4 Reconnect Procedure............A-5 220/230/240V Input.............A-5...

  • Page 9: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS max. rated Output Amps @% Duty Cycle (Based on a 10 minute cycle) (Example; 160A@35% for DC Stick and 200A@60% for AC/DC Balance TIG) MODEL PowerMaster 205 Voltage 1~AC220/230/ 240V 50/60Hz INPUT Fuse rating No-load Voltage current Adjusting Range 5~200A AC balance 10%~90 %...
  • Page 10 INSTALLATION Chart gives max. rated Output Amps @% Duty Cycle (Based on a 10 minute cycle) (Example; 160A@35% for DC Stick and 200A@60% for AC/DC Balance TIG) Using standard input cable for protected input supply 100% STICK(MMA) OUTPUT AMPS Wiring and protection based on the IEC60974.1 National Electric Code: Use a Super Lag type fuse or circuit breaker with a delay in tripping action.

  • Page 11: Select Suitable Location

    INSTALLATION SAFETY PRECAUTIONS Read entire installation section before starting installation. Never lift welder above personnel. TILTING ELECTRIC SHOCK can kill. Each machine must be placed on a secure, level ·Only qualified personnel should surface, either directly or on a recommended perform this installation.

  • Page 12: Machine Grounding And High Frequency Interference Protection

    INSTALLATION MACHINE GROUNDING AND HIGH following methods: FREQUENCY INTERFERENCE a) A metal underground water pipe in direct contact PROTECTION with the earth for ten feet or more. This welder must be grounded! See your local and b) A 3/4" (19mm) galvanized pipe or a 5/8" national electrical codes for proper grounding (16mm)solid galvanized iron, steel or copper rod methods.

  • Page 13: Reconnect Procedure

    INSTALLATION an individual branch circuit. Using fuses or circuit breakers smaller than 1Also called “inverse time” or “thermal/magnetic” recommended may result in "nuisance" shut-off circuit breakers. from welder inrush currents even if not welding at These circuit breakers have a delay in tripping action that decreases as the magnitude of the high currents.

  • Page 14: Work Cable Connection

    INSTALLATION ENGINE DRIVEN GENERATOR The Inverter machine can be operated on engine SHIELDING GAS CONNECTION driven generators as long as the 220/230/240 volt Obtain the necessary inert shielding gas (usually auxiliary meets the following conditions: argon). Connect the cylinder of gas with the .

  • Page 15: Operation

    OPERATION Read and understand this entire section before operating the machine. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. · Do not touch electrically live parts or electrode with skin or wet clothing. · Insulate yourself from work and ground. · Always wear dry insulating gloves. Read and follow "Electric Shock Warnings"...

  • Page 16: Product Description

    OPERATION PRODUCT DESCRIPTION RECOMMENDED QUIPMENT/INTERFACE The Precision TIG is a member of our field acclaimed Precision TIG family of industrial arc (See Installed Options in Accessories Section for welding power sources. Premium features include: more details) 1 Precise constant current output. The Precision TIG will be available as a basic 2 Full range square wave AC/DC TIG (GTAW) Machine (Only) and in Factory Basic module will...
  • Page 17 OPERATION CONTROLS AND SETTINGS All operator controls and adjustments are located on the case front of the TIG machine. Refer to Figure B.1 and the corresponding explanations. FIGURE B.1 CONTROL PANEL 1. FRONT PANEL 2. BACK PANEL 1.indication welding current 2.power switch 3.pulse current regulator...
  • Page 18 OPERATION For quick disconnect system using Twist-Mate 7.indicating light of power cable plugs Turn power on, it will illuminate indicating. 15. AC square wave Frequency 8. indicating light of over heat Regulating the knob, It selected -If the welder overheats due to blocked air flow, between 20 TO 250Hz.
  • Page 19 OPERATION * (a) Manufacturer's name and address the following welding sequence will occur. This * (b) Trademark sequence is shown in (2-step diagram 1) * (c) Model 2 STEP DIAGRAM 1 * (No) Serial number TORCH BUTTON ) The welding power source comprises a frequency converter followed by an transformer and rectifier that transforms input voltage into direct current.
  • Page 20 OPERATION Possible variations of this standard sequence are shown below. By releasing and re-pressing the TIG 4-Step Sequence torch trigger during the downslope step, the output With the 4-step Selected, the following welding will immediately drop to and hold at the Finish sequence will occur.

  • Page 21: Operating Steps

    OPERATION OPERATING STEPS WELDING IN TIG MODE 1 Connect the TIG torch and cable Twist-Mate quick connect plug to the Electrode/Gas output receptacle. This receptacle also contains an integral gas connection for the torch. Connect the work clamp to the work piece. 2 Set the TIG/MMA/CUT switch to "TIG".

  • Page 22: Dc Pulsed Tig

    OPERATION Increasing frequency constricts arc, STEEL TIG WELDING increases stability and improves weld quality. The TIG process is very effective for welding both FIGURE B.6 carbon steel alloy steel, especially applications requiring precision results. I(A) Electrode Negative Polarity is required. Since this DC TIG-NOT PULSED process does not include the removal of impurities, proper cleaning and preparation of the edges is...

  • Page 23: Gtaw Process

    OPERATION ·● Set the AC Balance control to maximum 70% desired. electrode negative. This can be reduced if the . ●Set the AC Frequency in the 100 to 120 Hz range. material welded is heavily oxidized, however This is a "Sweet Spot" for most aluminum starting at maximum and adjusting to less is applications.
  • Page 24 B-10 OPERATION B-10 Welder Function Summary and the side of the weld. Not all welds conditions will be Explanations. alike so more cleaning is required at times than others. Similarly, more penetration will be required at times than AC Frequency. others.

  • Page 25: Ac Tig Welding Quick Start Up

    B-11 OPERATION B-11 AC TIG WELDING QUICK START UP DC TIG WELDING QUICK START UP ELECTRIC SHOCK can kill. ELECTRIC SHOCK can kill. . Have an electrician install . Have an electrician install and service this equipment. and service this equipment. .
  • Page 26 B-12 OPERATION B-12 "Maximum" refers to a fully depressed Foot cleaning action but concentrates more heat on the Ampcontrol,or a fully extended Hand Ampcontrol. work. When the welder is in TIG modes activating the The AC waveform of the PRECISION TIG Ampcontrol energizes the electrode terminal and optimizes cleaning and heating of the work.
  • Page 27 B-13 OPERATION B-13...
  • Page 28 B-14 OPERATION B-14...
  • Page 29 B-15 OPERATION B-15...

  • Page 30: Welding In Stick Mode

    B-16 OPERATION B-16 WELDING IN STICK MODE will be electrically hot whenever the power 1 Put the electrode holder and cable quick connect switch is turned on. plug into the electrode output receptacle. Turn clockwise until tight. Connect the work clamp to the 5 Turn the power switch to "ON".
  • Page 31 B-17 OPERATION B-17 1. Turn on the power switch on the rear of the unit. Allow unit to cycle through its start up program. 2. Select the Stick mode with the HF/Lift Start/Stick selector switch. 3. Make sure electrode holder is connected to the positive terminal and the work clamp is connected to the negative connector.

  • Page 32: Cutting In Cut Mode

    B-18 OPERATION B-18 CUTTING IN CUT MODE 1 Put the Cutting torch and cable quick connect plug into the electrode output receptacle. Turn clockwise until tight. Connect the work clamp to the work piece. 2 Set the TIG/STICK/CUT switch to "cut". OPERATING NOTES: 1.
  • Page 33 B-19 OPERATION B-19...
  • Page 34 B-20 OPERATION B-20...
  • Page 35 B-21 OPERATION B-21...
  • Page 36 B-22 OPERATION B-22...

  • Page 37: Maintenance

    MAINTENANCE 7 SPARK GAP ADJUSTMENT SAFETY PRECAUTIONS The spark gap .020(.5mm) is set at the factory to a gap of 0.015 inches (0.4mm) See Figure D.1. This setting is adequate for most applications. Where ELECTRIC SHOCK can kill. less high frequency is desired, the setting can be ●...

  • Page 38: Troubleshooting

    TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by our Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 39 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS POSSIBLE AREAS OF RECOMMENDED PROBLEMS (SYMPTOMS) MISADJUSTMENTS COURSE OF ACTION 1. Make certain that the input power switch is in the "ON" position and machine is plugged in. 2. Check the input voltage at the Machine is Dead -No Output machine.
  • Page 40 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS POSSIBLE AREAS OF RECOMMENDED COURSE PROBLEMS (SYMPTOMS) MISADJUSTMENTS(S) OF ACTION 1. Welding application may exceed recommended duty cycle. Reduce the Machine regularly over duty cycle. heats - thermostat opens, 2.
  • Page 41 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual TIG MODE PROBLEMS POSSIBLE AREAS OF RECOMMENDED COURSE PROBLEMS (SYMPTOMS) MISADJUSTMENTS(S) OF ACTION 1. Problem may be caused by high frequency interference. Make sure that the machine is grounded properly according to the installation Machine output instructions.
  • Page 42 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual TIG MODE PROBLEMS POSSIBLE AREAS OF RECOMMENDED COURSE PROBLEMS (SYMPTOMS) MISADJUSTMENTS(S) OF ACTION 1. Clean any oily or organic contamination from the work piece. 2. Tungsten electrode may be contaminated. Replace or sharpen. Black areas along weld 3.Check for contaminated gas or leaks in bead...
  • Page 43 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual TIG WELD PROBLEMS POSSIBLE AREAS OF RECOMMENDED COURSE PROBLEMS (SYMPTOMS) MISADJUSTMENTS(S) OF ACTION 1. If the machine location is in a highly No high frequency. Machine dirty environment with conductive is in the TIG Mode and has contaminants, check and clean the spark normal output.
  • Page 44 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual STICK WELDING PROBLEMS POSSIBLE AREAS OF RECOMMENDED COURSE PROBLEMS (SYMPTOMS) MISADJUSTMENTS(S) OF ACTION Weld current may be set too high for electrode size. Reduce current control setting, or use a larger Stick electrode "Blasts Off"...
  • Page 45 DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

  • Page 46: Accessories

    ACCESSORIES Appendix FACTORY INSTALLED OPTIONS PACKING LIST ★ ★★★★★★★★★★★★★★★★★★★★★★★★★★★★★★★★★★★★★★★ PowerMaster 205 4 IN 1 MACHINE Ground clamp TIG welding torch Welding holder gas inlet pipe Air pressure Regulator flow meter Adjustable foot control Cutting torch Electrode Tip 1.0 Ceramic shieid Operation instructions Certificate of quality ━━━━━━━━━━━━━━━━━━━━━━━...
  • Page 47 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
  • Page 48 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...

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